FOSC 600 C and D I N S T A L L A T I O N I N S T R U C T I O N Fiber Optic Splice Closure 1.0 General Product Information The FOSC 600 fiber optic splice closure is a combination cable closure and splice organizer that uses compressed-gel cable seals to environmentally seal fiber cable splice points. The FOSC 600 closure is available in two sizes and several configurations, as described by the kit naming convention shown below: FOSC 600-abc-dd-e-fgh a = Closure size (C or D) b = Number of cable ports provided (4, 6, 8) 4 = one 4 - port gel block 6 = two 3 - port gel block 8 = two 4 - port gel block c = Configuration (B = Butt, I = Inline, R = Reverse Butt) dd = Capacity (or type) of splice trays 36 = D tray with six SM6 modules 72 = D tray with six SM12 modules R2 = Ribbon tray (24x12 splice capacity) NT = No trays (This is standard) e = Number of splice trays (0 for no trays is standard) f = Basket type (C, D, N for none, L for LBT-R mod) g = Number of ground feed-thru lugs (0, 2, or 4) h = Valve for flash-test (V for valve is standard) Cable Types and Sizes FOSC 600 C and D closures accommodate central core tube or loose buffer tube, and shielded or unshielded cables with single-strand fibers or ribbons. Two gel cable seals are available as illustrated below. Upper Lower --Small Ports-- ---Large Ports--- FOSC 600 # Min.-Max. # Min.-Max. Gel Seal Ports OD Ports OD 3-way 2.32-.79 in. 1 1.0-1.38 in. 8-20mm 25-35mm 3- way 4-way 2.32-.87 in. 2.39-1.1 in. 8-22mm 10-28mm 4- way Note: In the 4 port cable gel seal, if both the lower large ports have maximum cable diameters (1.1, 28mm) the maximum cable diameter in the upper small ports is.79 or 20mm.
Closure Splice Capacities Standard or Reverse Butt In-line Configuration Trays Splices Trays Splices 5 Standard Splice trays 3 Standard Splice Trays FOSC-ACC-D-Tray-36 180 FOSC-ACC-D-Tray -36 108 600C D-Tray-48 240 D-Tray-48 144 D-Tray-72 360 D-Tray-72 216 D-Tray-96 480 D-Tray-96 288 3 Ribbon Trays 2 Ribbon Trays FOSC-ACC-D-Tray-RIBN-24 864 FOSC=ACC-D-Tray-RIBN-24 576 9 Standard Splice Trays 7 Standard Splice Trays FOSC-ACC-D-Tray-36 324 FOSC-ACC-D-Tray-36 252 600D D-Tray-42 432 D-Tray-48 336 D-Tray-72 648 D-Tray-72 504 D-Tray-96 864 D-Tray-96 672 6 Ribbon Trays 4 Ribbon Trays FOSC-ACC-D-Tray-RIBN-24 1,728 FOSC-ACC-D-Tray-RIBN-24 1,152 Splice Types FOSC 600 C and D closures accommodate single or mass-fusion splices in standard or ribbon trays. Applications FOSC 600 C and D closures can house butt-configuration splices or in-line splices. The closures can be used for new construction or to retrofit existing splices. It is possible to remove existing closure housings and replace them with FOSC 600 closures because of the FOSC 600 closure s wraparound gel-filled cable seals. FOSC 600 closures are suitable for underground, buried, and aerial applications. 2.0 Standard Kit Components (May vary depending on kit ordered) Closure Top 1/4 Nut Driver (1) Closure Bottom Bond Wires (4) Gel Cable Seal (1) Spiral Tubing Gel Cable Seal Port Plugs (4) ID Label Cards Splice Tray (1) Slack Basket (1) Ribbon Transportation Tube Large Transportation Tube Plastic Bend Control (1) Alcohol Wipe Cable Attachment Assembly (1) Tie Wraps Hose Clamps Closure Mouting Brackets Strength Member Brackets (2 large, 2 small with Self-Tapping Screws) 3.0 Warnings 1. WARNING: Never look directly into the end of a fiber that may be carrying laser light. Laser light may be invisible and can damage your eyes. Viewing it directly does not cause pain. The iris of the eye will not close involuntarily as when viewing a bright light. Consequently, serious damage to the retina of the eye is possible. Should accidental eye exposure to laser light be suspected, arrange for an eye examination immediately. 2. WARNING: DO NOT use magnifiers in the presence of laser radiation. Diffused laser light can cause eye damage if focused with optical instruments. Should accidental eye exposure be suspected, arrange for an eye exam immediately. 3. The cleaning tissues provided in the kit are extremely flammable and should not be exposed to excessive heat or open flame. 4. Flash test the closure to no more than 5 psi. (40 kpa) Page 2
4.0 Required Tools and Materials You will need these tools and materials to install a FOSC 600 C or D closure: Snips and sheath knife Buffer tube cutter Assorted hand tools, such as a hacksaw or coping saw, screw drivers, pliers, Crescent wrenches, can wrench, needle-nose pliers 1/2 socket and ratchet or driver White marking pencil Locally approved cleaning solution for fibers Measuring tape Clean, dry cloths 5.0 Supplementary Kits The following supplementary kits are available for use with FOSC 600 C or D closures: Kit Name FOSC-ACC-D-Tray-36 FOSC-ACC-D-Tray-48 FOSC-ACC-D-Tray-72 FOSC-ACC-D-Tray-96- S60 FOSC-ACC-D-Tray-96- S45 FOSC-ACC-D-Tray-Ribbon Description D-size splice tray with six SM6 splice modules D-size splice tray with six SM8 splice modules D-size splice tray with six SM12 splice modules D-size splice tray with 8 FIST splice modules, 60mm D-size splice tray with 8 FIST splice modules, 45mm D-size ribbon tray with capacity for 24 ribbons or 288 fibers FOSC600-Gel-Block-4 One 4-way Gel Block (see page 1) FOSC600-Gel-Block-3 One 3-way Gel Block (see page 1) MEG Kit FOSC-600-Aerial- Bracket FOSC-ACC-Bond- Wire-9.5 6-wire or 3-wire MEG kits for individual cable grounding Aerial mounting bracket and hardware Ground wires (10) for attachment to B-bond Page 3
2. 1. 6.0 Open Closure 1. Loosen the captured bolts at each end of the closure with a 1/2" socket wrench. (Fig. A, Step 1) 2. Unlatch each of the latches in order, using a flatblade screwdriver to pry each latch open. Hooks must be completely disengaged and in the "up" position to avoid trapping the closure cover in place. (Fig. A, Step 2) 3. Lift the top half of the closure and set it aside. Fig. A 7.0 Cable Preparation Section Loose Fiber LBT Midspan 140-160 End 100 6.1 ` Central Core Midspan 140-160 End 100 Buffer tubes Bond wire Central member 1.25" (32mm).75" (19mm) Tab for bond clamp Outer cable sheath Fig. 1 Ribbon Loose Buffer MIdspan 140-160 Tube Ribbon End 100 6.2 (LBTR) Central Core Midspan 140-160 End 100 Reverse Butt Configuration 7 LBTR Midspan 125 End 65 To prepare the ends or midspan entry of central core tube (CCT) cable follow steps in section 7.2. 7.1 Loose Buffer Tube (LBT) Cable Preparation To prepare the ends or a midspan entry of loose buffer tube cable, follow these steps: 1. Ring cut and remove a length of outer cable sheath and shield (if present) as shown in chart above. Remove the aramid and fiber yarns to each ring cut. 1" (25mm) 2. Initially, cut central member approx. 6 (15cm) from each sheath ring cut. 3. Cut the strength member 1.25 (32mm) from each sheath ring cut. F4.172 Fig. 2 4. If a shield is present in the cable, tab the cable 3/4 (19mm) from each sheath ring cut and attach a supplied bond wire to the tab in the sheath. Tape bonding wire in place. (Fig. 1) Page 4
5. To install a b-bond on double-armored cable, see Fig. 2 and 3. Outer sheath Outer shield F4.173 Bond wire eyelet Inner shield Fig. 3 6. If fibers are to be routed directly to splice tray, cut the buffer tube to 4 and install 30 to 35 of spiral tubing. Use a tie-wrap to secure spiral tubing to buffer tube. 7. If securing and storing slack in basket, cut buffer tube to 10 and install appropriate length of spiral tubing to route fibers to tray. 8. For 864-fiber, cut tubes to 9, install spiral tubing and secure to tube holders in slack basket. 9. Clean cable end (7 ) with supplied cleaning tissue. 7.2 Central Core Tube (CCT) Loose Fiber or Ribbon Cable Preparation To prepare the ends or a midspan entry of central core tube cable, follow these steps: Fiber groups or Ribbons 1. Remove length of cable jacket and shield as shown in the chart in section 6.0. 10" (255mm) 1.25" (32mm).75" (19mm) Central core tube 1.25" Metal strength members Shield Ring cut Outer cable sheath Fig. 4 2. Remove all but 3/4 of shield, if present, at each ring cut. 3. Cut each metal strength member 1.25 (32mm) from each sheath ring cut or from the edge of the shield if present. 4. For shielded cable attach a supplied bond wire to the exposed shield. Tape bonding wire in place. Note: If you are using a slack basket and the cable will enter through the lower (larger) ports of the gel block, see Figure 4. If you are not using a slack basket, see Figure 5, then skip to step 6. Fiber groups or Ribbons 5. Ring cut the core tube 10 (255mm) past each sheath ring cut, or 10 (255mm) from the edge of the shield, if present. Skip to step 8. 6. Ring cut the core tube 2 (50mm) past each sheath ring cut or 2 (50mm) from the edge of the shield, if present. 2" (50mm) 1.25" (32mm).75" (19mm) Central core tube 1.25" Metal strength members Shield Ring cut Outer cable sheath Fig. 5 7. Cut a 9 (23cm) length of spiral wrap and install it over the core tube. Secure to the core tube with tie wraps. 8. Clean the cable (7 ) with supplied cleaning tissue. Page 5
8.0 Open Other Ports, if necessary Fig. 6 Tray tower L Bracket 1. It may be necessary to open additional ports in the closure. (Fig. 6) 2. Look closely at the factory opened port to determine where to cut the other ports. With top and bottom half shells securely latched and bolted together, use a hacksaw (a coping saw works best, if available) to saw open the selected port, cutting completely through the port. (Fig. 7) Deburr edges. 3. For ports other than the factory-opened port, install the lower half of a cable attachment assembly in the bottom half of the closure near the port with two supplied socket-head cap screws. (The assembly for the factory-opened port is factory-installed; refer to that assembly for correct positioning.) (Fig. 8) Fig. 7 Butt-splice In-line splice Cut here or here to open desired port. 9.0 Cable Attachments 1. Place the opened gel block into the appropriate port. Position the gel block tabs in the open port slots with the "tail" outside of the closure. The larger port(s) in the gel block should be in the bottom of the closure. (Fig. 9) 2. Decide which cables will go in each gel block port based on cable diameter and gel block port size. Fill bottom (larger) port(s) first with larger-diameter cables, then fill top port(s) with smaller-diameter cables. Fig. 8 Pins (2) Upper Lower --Small Ports-- ---Large Ports--- FOSC 600 # Min.-Max. # Min.-Max. Gel Seal Ports OD Ports OD 3-way 2.32-.79 in. 1 1.0-1.38 in. 8-20mm 25-35mm 3- way Cable attachment assembly 2. Sheath retention clips 1. 4-way 2.32-.87 in. 2.39-1.1 in. 8-22mm 10-28mm 4- way Strength member attachment bracket Note: In the 4 port cable gel seal, if both the lower large ports have max. cable diameters (1.0, 25mm) the max. cable diameter in the upper small ports is.79 or 20mm. 3. Remove the top cable attachment assembly by removing the two pins that hold it in place. (Fig. 9) Tail Fig. 9 Page 6
Ring cut Strength member Note: There are two sizes of strength member brackets and lugs in the kit. Use the large bracket and lug for cables with larger strength members, and the small strength member bracket and lug for smaller cables. 4. If using the larger strength member attachment bracket (Fig. 10), trim the strength member to 1-3/4 length from the ring cut. Strength member attachment bracket Fig. 10: Loose Buffer Tube with central member (use center prong) Strength member 5. If using the small strength member attachment bracket (Fig. 10), trim the strength member to 1-1/4 length from the ring cut. 6. If needed, remove the unused prongs of the strength member bracket by using pliers to bend them sharply away from the cable and cutting them off. Note: Position bond clamp 180 from strength member attachment bracket. 7. Install the strength member bracket into the bottom cable attachment assembly by pushing the metal tab into the slot. Strength member bracket and grounding attachments should be opposite each other on the cable. Fig. 11: Central Core Tube with dual strength members (use two outer prongs). Cut unneeded prongs. 8. Adjust the sheath retention clips until they grip the cable sheath. Wrap a hose clamp around the sheath retention clips and cable and use a quarterinch nut driver to tighten the hose clamp in place. (Fig. 12) Tighten the clamp such that the retention teeth fully seat into the cable assembly. Do not tighten the clamp so much that it deforms. Note: The sheath retention clips should not extend past the ring cut of the cable. Note: For cable with no rigid strength member, the strength member attachment is not required. Fig. 12 Note: Position the hose clamp bolts to the sides of the cable. They could become trapped between the cables and the closure or interfere with upper cable attachments if left on the top or bottom. 9. If cables are to be installed in the top cable attachment assembly, repeat Steps 3-8 for those cables. 10. Re-install top cable attachment assembly onto bottom cable attachment assembly and secure in place with two pins removed in Step 3. 11. Attach bond wire eyelets to ground feedthrough studs for bonding to the closure. For individual external bonding, a FOSC MEG (multiple external ground) kit is required. Page 7
In-Line Splice Butt Splice Hinge point Distribution or out Feeder or in Splice tray Fig. 13 10.0 Fiber Management 1. Whether using in-line or butt configuration, all incoming tubes should first be routed to slack storage area under splice trays. 2. Flexible buffer tubes can then be routed to feeder side of splice trays and secured for splicing. 3. Rigid tubes and any tubes containing ribbons must be terminated in slack storage area. Individual fiber or ribbon groups can then be routed to splice trays with spiral wrap or other appropriate transportation tubing. See figure 13 for standard routing diagrams for both butt and in-line configurations. Note: LBT and LBTR tubes can be stored under splice trays without slack basket and secured with red Velcro straps. Reverse Butt Configuration A- Preferred Method of Routing Splice tray B- Alternate Method of Routing Tray support latch Fig. 13A Hinge point Fig. 14 4. If multiple trays are present, fill the bottom tray first. Use the red tray support latch attached to bottom of the second tray to hold it out of the way. (Fig. 14) 5. Remove the tray cover and route the feeder (in) and distribution (out) tubes to the appropriate side of the tray (Fig. 15) 6. Mark each tube 1/4 beyond the tie-down slots. Use a buffer tube cutter to cut each tube at the mark, and remove the excess tube from each fiber group. (Fig. 15) 7. Secure the transportation tubes to the tray with tie wraps. Tubes will stack under the tie wrap as shown. (Fig 16) 8. Arrange the fiber around the tray for storage. Replace the tray cover. 9. Repeat steps 1-5 for each tray until all fiber has been stored in a tray. Note: Buffer tubes containing ribbon cannot be routed directly to splice tray. Note: L version will accommodate larger loops of slack tubes in tray tower cutout. (See General Product Information, page 1). 10. Reverse Butt Configuration (Fig. 13A) Note: Standard butt configuration has cable seals that hinge end of closure. In reverse butt, cable seals are at opposite end as shown. This configuration may be needed if the following conditions exist: Reverse point of loose tubes does not fall in center of midspan opening. Uncut ribbons from LBTR or RILT cables are to be stored on tray. Page 8
In this configuration the top half of the cable strain-relief assembly should not be installed. If the upper ports are needed for cable entry, standard splice trays should be shifted up one position and ribbon trays up two positions to clear the installed top assembly. Fig. 15 Distribution (out) 10.1 Add Intertray Jumpers If fiber placed on one tray is to be spliced with fiber from another tray or basket, you must use an intertray jumper to route the fiber to the desired tray. To create an intertray jumper, follow these steps: 1. Place appropriate identification makers on a transportation tube. (Intertray ID markers are marked 1TO through 8TO and 1 through 8, to indicate which tray the jumper came from and which tray it is going to.) 2. Thread the desired fibers through the marked transportation tube (now called the intertray jumper). 3. Secure one end of the intertray jumper to the originating splice tray with two tie wraps. If you have to remove existing tie wraps, cut and replace them one at a time to avoid moving existing transportation tubes. 4. Guide the jumper through the opening in the tray mounting bracket to the appropriate destination tray and position it in the tray. (Fig 17) 5. With a pen, mark the jumper 1/4 beyond the tie wrap slot. Use the buffer tube cutter to cut the jumper at the mark, and secure the jumper to the splice tray with two tie wraps. The fibers can now be stored or spliced. 10.2 Splice Fibers And Store On Trays Fiber splicing should be done in compliance with companyapproved practices. This section outlines some basic splice organizing techniques to be followed when using the FOSC 600 closure. 1. Always begin splicing with the bottom tray. Lift the remaining trays and secure them with the red tray support on the underside of the second tray. 2. Remove all stored, unspliced fibers from the tray and clean those that will be spliced. Refer to the splice manufacturer s instructions for directions on fiber splicing. Fig. 16 Fig. 17 Pen mark Feeder (in) Distribution (Out) cable side Feeder (In) cable side Tray support latch F4.179 Intertray jumper Page 9
GTE SIECOR AT & T 3M Fibrlok 3. Store the first completed splice in the top splice slot (the slot farthest from the hinge). Coil the slack loops around the tray in an orderly fashion. The six splice modules can be moved or removed to accommodate your splice arrangement; however, the lowest splice module (the one closest to the hinge) can not be closer to the hinge than its position indicates in Figure 19. No more than six modules can be placed in one splice tray. Numbers of splices accommodated by this closure are listed in Section 1. F4.125 Fig. 18 Note: Protect and strain-relieve fusion splices with fusion splice support sleeve or similar company-approved devices. It is not necessary to use silicone or similar compounds to secure the fiber in the splice holders. 4. Subsequent splices should be stored in the tray from the top slot down. Slack loops can be secured under the tabs around the outside edges of the tray and in the spaces between splice modules. (Fig 18) 5. When splicing is complete in the tray, replace the tray cover. Velcro strap 6. Secure all trays to the bottom tray bracket with the Velcro fastener strap as shown. (Fig 19) F4.126 Fig. 19 11. Gel Block Installation 1. With all cables in place, close and lock top of gel block. Use needle-nose pliers to pull locking tab up and over locking pin. 2. Insert one cable port plug into each empty cable port before tail is activated. (Fig. 20) Note: Should gel block become dirty, rinse in clean water only. Fig. 20 Page 10
12. Moving and Adjusting the Slack Basket for In-Line Configurations Although your closure may be set up for Butt Splicing, it may be converted to inline configurations if necessary. 1. Remove the Phillips screw that secures the nonhinged end of the slack basket to the closure body. (Fig. 21) 2. Remove the slack basket from the closure. 3. Install a spacer as shown in Figure 22, using the same Phillips-head screw. Fig. 21 4. Remove the plastic insert from the slack basket and compress the basket. (Fig. 23) 5. Reinstall the plastic insert to secure the basket. (Fig. 23) slack basket spacer for in-line applications 6. Install the slack basket in the second position from the bottom in the closure backbone. (Fig. 24) Important: Instructions for routing slack into slack basket and storing fibers on trays are included in the Tray Kit Installation Instructions (one for regular trays and one for ribbon trays). Fig. 22 slack basket position 2 for in-line configurations 2. 1. slack basket position 1 for butt-splice configurations Fig. 23 Fig. 24 Page 11
13. If No Slack Bracket Is Used Additional bend control device 1. Install round, plastic bend control device in bottom of closure with supplied Phillips-head screw. (Fig. 25) 2. Stack additional bend control devices to support splice trays in a level position. Plastic bend control device 14. Sealing the Closure 1. Make sure that the rubber gasket in the bottom half of the closure is clean and seated in the groove. 2. Pull up all hooks and latches around the closure top shell. Place the top half of the closure body onto the bottom half, making sure that the latches are properly aligned. To do this, turn top half upside down and at a 45 degree angle. The latches should fall into place. Fig. 25 3. Use a 1/2" socket to tighten the captured bolt at each end of the closure (two bolts, total). (Figure 26, Step 2) 1. 2. 3. 4. Fasten all latches around the outside of the closure by inserting a flat-blade screwdriver into each latch. Go back to bolts to make sure they are tight. (Figure 26, Step 1) 5. Twist the "tail" of each gel block clockwise to seal cables. When the tail reaches its physical stop, the seal is complete. Insert a screwdriver through the loop in the tail, or use a Crescent wrench to apply extra torque, if required. (Figure 26, Step 3) Note: Do not use a drill to turn the tail as this could cause damage to the gel seal. Fig. 26 Page 12
15. Testing the Closure Seal Pressure test the closure with no more than 5 psi. Thoroughly soap all seals and the valve to check for seal integrity. Important: After flash testing, bleed all pressure from closure through the valve. Wall Mounting Fig. 27 16. Mounting the Closure See illustrations for installing appropriate mounting hardware. If the closure is to be direct buried or susceptible to extreme cold temperature impact, the closure should be oriented with the parting line in the vertical plane. Wall mounting (Fig. 27) Pole mounting (Fig. 28) Aerial mounting (Fig. 29) brackets sold seprately Pole Mounting (use straps or bolts) Fig. 28 Aerial mounting on Self-supportive Cable (ADSS). (Fig. 30) Pipe Mounting (Fig. 31) Aerial Mounting Fig. 29 Separate here for re-entry Aerial Mount on Self-supportive Cable Fig. 30 Page 13
Pipe Mount Horizontal Pipe Mount Vertical 17. Re-entering Closure Or Adding a Cable to an Existing Closure To open a previously installed closure: 1. Loosen each installed gel block by twisting the tail counterclockwise. Insert a screwdriver through the loop in the tail, or use a Crescent wrench to apply extra torque, if required. (Fig. 32) Step 1 2. Loosen the captured bolts at each end of the closure with a 1/2" socket wrench. (Fig. 32) Step 2 3. Unlatch each of the latches in order using a flatblade screwdriver to pry each latch open. Hooks must be completely disengaged and in the "up" position so they don t trap the closure cover in place. (Fig. 32) Step 3 4. Lift the top half of the closure and set it aside. Pipe Mounting Fig. 31 If necessary, additional ports can be opened in the closure to accommodate new cables (see Section 7). If new ports are opened, new gel block kits are required (see chart, page 1). Secure cables in place as described in Section 8. Cable routing and fiber routing/splicing are described in the Tray Kit documentation supplied with the trays. Re-sealing the closure is described in Sections 13 and 14. 2. 3. 1. Fig. 32 Can bend away from cables For technical assistance, contact your local Tyco Electronics representative or call (919) 552-3811, Monday through Friday, 8 AM to 5 PM EST. Ask for Fiber Engineering Services. Page 14
Tyco Electronics Corporation Telecom Outside Plant 8000 Purfoy Road Fuquay-Varina, NC 27526-3000 Tel: 919 557-8900 Fax: 919 557-8498 FOSC 600 is a trademark of Tyco Electronics Corporation. Crescent is a trademark of Cooper Brands, Inc. Velcro is a trademark of Velcro Industries. The information given herein, including drawings, illustrations and schematics which are intended for illustration purposes only, is believed to be reliable. However, Tyco Electronics makes no warranties as to its accuracy or completeness and disclaims any liability in connection with its use. Tyco Electronics obligations shall only be as set forth in Tyco Electronics Standard Terms and Conditions of Sale for this product and in no case will Tyco Electronics be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use or misuse of the product. Users of Tyco Electronics products should make their own evaluation to determine the suitability of each such product for the specific application. 2003 Tyco Electronics Corporation Printed in USA PML MP0310 F392..08/06